Knob construction



y 1957 J. J. MEYER 2,793,899

KNOB CONSTRUCTION Filed March 21, 1956 2 Sheets-Sheet 1 'I'I'II'I'I'I'I'II w.

v'IIIIIIIIIIIIIIJIJJJJIII INVENTOR I M ECO/Z77, J 76;

A ATTORNEY y 1957 J. J. MEYER 2,793,899

KNOB CONSTRUCTION Filed March 21, 1956 2 Sheets-Sheet 2 INVENTOR John 1 Me 27' /L:/) ATTORNEY nite.

KNOB CONSTRUCTION John JiMeyer, fLeominster, -Mass., as'signor-to Independent LockCompany, Fitchburg, Mass, a corporation of Massachusetts Application March 21,1956, Serial No. 573,020

8 Claims. :(Cl. 292347) This invention relates to knob constructions, more particularly to'sheet metal knobs.

s My invention is concerned with theprovision of door knobs, particularly of the type employedin cylindrical locks and has for its object effecting economies in producing such knobs'by employing a core of sheet metal tubing which integrates a shank portion and knob portion, and ornamental sheathing of more decorative material, such as sheet brass, bronze, aluminum. More specifically,

a thin, decorative sheathing, such as thin gauge sheetbrass, aluminum which is capable of being spun and formed around the core, whereby high economies are effected. I

Known to me is the provision of procedures for forming door knobs of composite components in which base materials such as cast iron or other inexpensive metal has united to its surface, brass, silver or similar material. Such castings require costly finishing operations such as turning and the like.

Known to me also is the provision of knobs byenveloping a mandrel with a cup-shaped shell which is spun to assume the shape of the mandrel. Such operation is limited to smoothly outlined convex surfaces and relatively heavy gauge sheeting of the enveloping material to secure a bulbous or spheroidal outline, and requires the use of a separately :formed costly shank, finished to receive and to be incorporated in thecomposite structure. The resultant assembly is incapable of providing special shapes, particularly those having shallow or sharp re- ,Sitates PatentO ice 2,793,899 YEW-2s, .1957

l atented referenceto the accompanying drawing, forming a part hereon, in which Figure 1 is a longitudinal, sectional view of a decorafive-component entering into the production of a knob in accordance with my innvention;

Figure 2 is a, partially assembled view of thesame, with a core in accordance withmy invention; 7

Figure 3 is a longitudinal, sectional view of the assembly;

Figures *4 to8 are fragmentary sectional views of different embodiments.

Making reference to the drawing, one element in the preliminary formation of a knob in accordance with my invention resides in the provision of a cup-shaped blank 10 which is generally cylindricalyhaving a mouth portion 11 and a closed-end12,'preliminarily shaped with a concave front facing surface '13, peripherally merging into gradual re-entrant folds 14 atthe corners 15. This cup may be made of thinsheeting, such as brass, in the .gauge of the magnitude ranging from 1015 to .050. Sheeting of this gauge would ordinarily be inadequate to form a door knob or-t-o withstand spinning operations to interpose adjacent the forward face abrupt re-entrant angles to outline an ornamental design.

According to my invention, 1 first provide a core 16 of steel, initiallytubularly formed 'andincluding a shank portion 17, a bulbous portion 18, integrally joined by a flange '1'9-forming opposed re-entrant folds 2t and 21 at acute angles. A facing engaging edge 22 provides a rim outlining a slightly dished supporting seat 23, upon which may be centered by concentricity a concave reinforcing disk 24. This disk is-made of metal of at least the same relative thickness as the core 16. Co-terminous with .the'seat 23,'With the parts so assembled, the cupsha-ped envelope is brought 'into covering position, as shown in Figure 2, nesting'the initially formed concave front facingfsurface portion 13 within the concave face Of'IhQdlSk 24.

In this position, the assembly may be spun to shape the cup-shaped envelope 10 into close contact, conform ing to the core 16 radjacentt'he sharp corner outlined by the perimeter 25 of the c'lisk'24 and the extreme edges of entrant angles desirable in producing highly aesthetic shapes.

Accordingly, it is an object of my invention to provide a door knob in which a shank portion and a bulbous portion are integrally joined and formed from tubular stock, open at its opposite ends, and made of base metal,

holding an independently outlining decorative supporting disk which may be held on the seat to outline thereon shapes having re-entrant angles of decorative outline employing thin sheets which respond readily to more complex shaping operations Without sacrificing ruggedness.

To attain these objects and such further objects as may appear herein or be hereinafter pointed out, I make the seat 23:0utlining ashoulder23a.

*Rearwardly, the edge 11 is spun into enveloping position about the fold 20, to provide the finished corner fold 26, leaving a skirt portion 27 enclosed within the fold 21, the skirt beingthereby shielded by the overhang to one side of the-fold 26.

By the foregoing operation, no special care need be exercised in forming the ornamental re-entr'ant angle or corner 28, whether notched or smoothly merging, as shown in the preferred example in the corner 28. No special integration by soldering, brazing or welding need be effected between the disk 24 and body 16, as the seat 23 centers the disk 24 during the spinning operation, making the enveloping and conforming operations possible by simple spinning action, notwithstanding the fragile nature -of the sheeting of which the cup-shaped member 10 is made. The leading edge of the corner 28 of the shell is rigidly supported with sheets of the gauge within the range specified.

While I have shown and described the formation of a knob or handgripping assembly in which the forward end of the tubular core 16 has seated thereon a self-centering concave reinforcing disk of continuous outline, may, where-it is found desirable, alter this to provide a'knob which is arranged to carry a key operated assembly or a push button dogging assembly. This, I efiect by providing the forward end with a bearing outlining aperture. For this purpose making reference to Figure 4, I may .provide the core 16 with a concave disk 24b whose axial portion has a boring or circular cutout 29. This boring or cutout corresponds substantially to the diameter of a keyoperated tumbler assembly. The peripheral edge 25b of this disk is aligned substantially with the edge of the core. The convex face is seated upon the dished seat 2312 to self-center the concave surface of the disk 24b thereon. In this position the cup shaped blank 10b may be spun into position to conform to the core and seated reinforcing disk in the manner previously described, except that the axial portion of the cup shaped blank is spun inward- 1y to provide the flange 26b and form a facing 30 of the sheeting material for the wall defining the cutout 29. The peripheral edge 31 may be spun around the inner wall of the cutout of the disk 2411 further to lock the relatively thin sheeting into engaging position.

As in the prior embodiments, the edge 23b of the core 16 forms a self-centering dished seat to permit simple spinning operations to be carried over this reinforcing disk without special interlocking or integration of the disk and core to resist the pressure and force spinning operation in applying the enveloping sheeting of which the cup shaped envelope 10 is constituted.

While I have described and illustrated a knob construction in which the forward end comprises a concave reinforcing disk in that the peripheral edges afford a selfcentering surface cooperating with the dished seat to hold the reinforcing disk in seated position Without special integration, I may retain some of the benefits of my invention by so forming only the peripheral edge of the reinforcing disk with the dished or self-centering seat and alter the balance of the disk in accordance with some desired ornamental contour. For this purpose I refer to Figures 5 to 8.

In Figure 5, the core 16 is formed as in the first embodiment to provide at its forward edge a dished seat 23 on the extreme, leading edge. The disk 24d inthis embodiment is convexly formed. Peripherally the edge of the disk 24d is formed with an outwardly turned flange 25d by outwardly bending the periphery along the folded edge 34 thereby presenting a tapering flange 35 conforming substantially to the seat 23 while bringing the free edge 25d substantially coterminous with the outer face of the core 16 in the fully wedged position.

In this form of construction, substantially all of the benefits of the self-centering features previously described are provided to permit the spinning of the sheeting with the thin gauge ornamental sheeting in a manner previously described retaining nonetheless an almost complete spheroidal outline.

With the embodiment illustrated in Figure 5, further ornamental effects may be carried out as illustrated in Figure 6, wherein the cup shaped sheeting s may be spun at its forward end 13a to shape the sheeting of which the cup shaped member ltle is made to provide a ring portion 14a, spinning the same about the flange 25d and into the internal annulus or groove 25e. Here again, the general frusto-conically shaped centering flange 25d, bearing against the dished seat 23, wedges the flange 24d upon its seat, to resist the spinning stresses, including such as may be involved in forming the indented ring portion 14e.

In Figures 7 and 8, the principle of construction more specifically shown in Figures 5 and 6 is further illustrated wherein the disks 24) and 24g, respectively, are each formed with facing edges 22] and 22g. In the former, a flat continuous face is illustrated; in the latter, a'slight crowning is effected on the central area, each disposed or shaped from the general spheroidal configuration of the main body of the knob outline.

In these forms, the flanges 25] and 25g, respectively, are arranged with respect to the facing portions 22) and 22g, defined by the annular edges 26 and 26g to outline a deep droove or internal annulus 27f and 27g, not only to increase the area of the frusto-conic section but to provide a more elastic or resilient overhang, thereby 4 more intimately and frictionally Wedgingthe flanges 257' and 25g of each of the dished seats 23. The spinning operation of the thin, ornamental sheeting 101 and 10g from the corresponding cup-shaped blank may proceed as in the prior embodiments.

In general, it will thus be observed that by the con struction described relatively heavy gauge sheet iron or steel tubing, open at its opposite ends, may be shaped preliminarily to provide an integral shank portion and a bulbous handgripping portion of general spheroidal outline, and by shaping the free forward end thereof to constrict it, a dished seat or conic section is outlined. This shape of the forward end as described serves to form a supporting shoulder into which or in relation to which a reinforcing disk may be positioned to receive such reinforcing disk with highly desirable results in the further handling to form a laminated construction and lock assembly. The positioning of the disk in this manner causes a centering of this member which, under pressure, particularly in the spinning of a cup of thin, ornamental sheeting, more intimately wedges the reinforcing disk i nto position to resist the stresses of spinning and shaping, without entailing costly integrating operations to join the disk to the main body of the core or require costly jigs or dies to make the spinning operation possible. Likewise the same core may be used alternately with differ-- ently shaped disks and disks which may be used to support a key tumbler or push button assembly and effect great economies in manufacturing assemblies.

Having thus described my invention and illustrated its use, what I claim as new and desire to secure by Letters Patent is- 1. A knob construction for locks or the like comprising a substantially tubular core shaped into an integral shank supporting portion at one end and a substantially spheroidal handgripping portion at the other end, an open edge of the latter outlining a seat angularly rearwardly extended to the axis and shank portion of the core, a closure disk means for said spheroidal portion having a selfcentering peripheral edge engaging said seat and cooperating under pressure to be retained axially on said seat and an encasing envelope for said shell and disk to encase the core and disk.

2. A knob construction for locks or the like having a handgripping portion comprising a substantially tubular core of rigid sheet iron shaped into a bulbous handgripping shell portion, terminating in a reduced edge outlining an opening having a dished seat formed across the edge thickness of said sheet, a reinforcing disk as a closure for said opening having a self-centering edge centered on said seat and a cup shaped envelope of thin sheet metal spun into conforming contour of said shell and said disk.

3. A knob construction for locks or the like having a handgripping portion and a shank portion connected to each other and comprising a tubular core of sheet iron extended from the shank and outlining a substantially spheroidal handgripping portion, a small zone of which defining an axially extended cutout, the thickness of the sheet at such cutout outlining a seat which is dished, a reinforcing closure disk for said cutout having a peripheral portion conformingly outlined to said seat and arranged to be wedged on said seat under pressure of encasing an ornamental thin gauged sheet metal envelope about said portion and disk.

4. A knob construction for locks or the like having a handgripping portion and a shank portion connected to each other and comprising a tubular core of sheet iron extended from the shank and outlining a substan' tially spheroidal handgripping portion, a small zone of which defining an axially extended cutout, the thickness of the sheet at such cutout outlining a seat which is dished, a reinforcing closure disk for said cutout having a peripheral portion conformingly outlined, by a flange bent on said disk, to said sheet and arranged to be wedged on said seat under pressure of encasing an ornamental thin gauged sheet metal envelope about said portion and disk.

5. A knob construction for locks or the like having a handgripping portion and a shank portion connected to each other and comprising a tubular core of sheet iron extended from the shank and outlining a substantially spheroidal handgripping portion, a small zone of which defining an axially extended cutout, the thickness of the sheet at such cutout outlining a seat which is dished, a reinforcing closure disk for said cutout having a peripheral portion conformingly outlined, by a resilient flange outwardly bent on said disk, to said seat and arranged to be wedged on said seat under pressure of. encasing an ornamental thin gauged sheet metal envelope about said portion and disk.

6. A laminated knob construction for looks or the like having a handgripping portion comprising a shell of sheet metal comprising a spheroidal handgripping 20 portion, a segmented zone of which outlines a cutout forwardly on the said portion and a dished seat across the thickness of the shell, a closure disk, a peripheral edge portion of which is coterminous with'the edges of the spheroidal portion outlining the said segmented portion of said handgripping portion and includes a seat contacting edge axially centering the disk and a concentric depressed portion on said disk, and an integral enveloping cup centered by said depressed portion and spun into position encasing said shell and disk.

7. A laminated knob construction for locks or the like in accordance with claim 6, wherein said shell is a tubular sheet iron having an integral shank portion outlining a reentrant acute angle fold, into which edges said enveloping cup is extended.

8. A laminated knob construction for locks or the like in accordance with claim 6, wherein said closure disk has a peripheral flange conforming to said seat and, said envelope is spun to conform to said flange.

References Cited in the file of this patent UNITED STATES PATENTS 159,509 Haines Feb. 9, 1875 190,349 McManus May 1, 1877 482,953 Wihnot Sept. 20, 1892 2,496,714 Haines Feb. 7, 1950 

